1982 KZ440 LTD | Street Tracker Build

Hello all!

I had a topic going in another part of the forum regarding a tank swap but it started going in the direction of a build thread, so I figured it was about time I came over and started a proper thread.

So, here's how I got her, about three years ago outside Council Bluffs, Iowa. The story that came with the bike was pretty interesting. Apparently it was used at a local dealership in a display lineup that featured a couple Kawa bikes from each decade since the 70s. The bike overall reflected the little to no use. The entire thing was spotless except for a few odd modifications by the PO. Most noticeably, the airbox had gotten the backyard mechanic treatment and the inside of the carbs was a war zone, like someone tried to pry the jets out with a flathead screwdriver. Two of the jets weren't even in there.

Something doesn't quite look "stock" about this bit.

Flash forward about three years and this is how she stands.

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A list of progress over the year and a half:

+ switched out stock bars for black Euro bars with Biltwell grips
+ converted front signals to LED / relocated to headlight
+ painted front fender
+ lowered triple tree 1.75'' down fork
+ painted front / rear rims
+ purchased a 1979 kz400-B tank (being treated for internal rust)
+ relocated starter button to electrical tray under seat pan
+ wrapped header pipes
+ single carb conversion with 11th Hour Industries 2-1 manifold and Mikuni VM32 / UNI filter
+ fiberglassed a new seat pan with room underneath for electrical tray
+ upgraded regulator / rectifier
+ removed rear fender
+ updated rear tail light to LED

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Stil to do, in order:

+ finalize seat design and upholstery
+ find a tank cap
+ replace "new" tank petcock gaskets
+ clean up / rewire harness and components / electrical tray
+ clean up battery area (new battery box?)
+ update master cylinder
+ replace throttle / brake cables
+ update rear signals to LED
+ upgrade to lithium battery?

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And that's about it for now. I've got plenty to work on over the summer, but at least the bike isn't in boxes. The whole philosophy behind the project is using the native bones to rebuild something really fun to ride. No rearsets. No clip-ons. No chopping up the frame. No spoked wheels. Just reimagining what can be done with an often-unwanted stock LTD.

Anyways, I'm having a blast, and the more I work on this little bomber, the more I love it.

I'll continue updating you guys on the progress over the next several months and back-fill the process with photos if I come across them. Feel free to drop by with any questions, comments, or suggestions. I'm new to the online forum community, but it's something I've been wanting to get more involved with. Thanks!

I like your approach to the build, but I do wonder about one thing. Have you fully compressed the forks and turned the bars from lock to lock to insure that the wheel and fender will clear the frame and exhaust pipes? If not, you may have an accident in the making.

Hey texaskz,

Good call. I did compress the fork all the way down and turned the full range to make sure sure there was at least a solid inch or two of clearance. This was also a concern when fitting the non-stock tank, as well. All of my garage tests are showing full range of motion / clearance on both counts.

Thanks for the heads up!

Good deal. It's certainly better to find those things out early rather than late.

Went out for a much needed ride after work and noticed the tach failed on the way back. Did a little snooping around and found this after a few minutes. Time to learn how to replace a tach cable. Haha

A smaller but fatter front tire would give it the tracker look.

where could one find a smaller but fatter front tire that is compatible ?

You would need to change wheels, a smaller front wheel with fatter tire. Look up some flat track bikes pics.

Kidkawie wrote: You would need to change wheels, a smaller front wheel with fatter tire. Look up some flat track bikes pics.

for the 440s i've gotten the impression that there aren't many wheels that are compatible